Professional Documents
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PROCESSES
(M–SCHEME)
Principal
Sri Renugambal Polytechnic College,
Polur – 606 907.
KAL PATHIPPAGAM– 99446 50380, 96266 26747
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KAL PATHIPPAGAM– 99446 50380, 96266 26747
14. Give the uses of lifter, sprue pin and strike off bar.
1) Lifter is used to remove the loose sand from the mould and
to repair the broken surfaces of the mould.
2) Sprue pin is used for making holes for runner and riser in
the mould.
3) Strike of bar is used for removing excess sand from the
mould after ramming.
15. What are the uses of swab, gate cutter and draw spike?
1) It is used for applying small amount of water around the
pattern before removing it from the mould.
2) It is used for cutting gate in the mould.
3) It is used for removing the pattern from the mould.
16. What are cope and drag?
If the moulding is done with two boxes, the upper box is called
cope and the lower box is called drag. The two boxes are
aligned correctly with the help of dowel pin
17. List out the various binders used in moulding sand? Give
an example.
a) Clay type binders : Bentonite and kalvanite
b) Organic binders : Wood, resin, linseed oil and dextrin.
c) Inorganic binders : Portland cement and sodium silicate
18. List out the properties of moulding sand.
1. Porosity 2. Plasticity 3. Adhesiveness
4. Cohesiveness 5. Refractoriness 6. Collapsibility
19. What are the types of moulding sand?
1. Green sand 2. Dry sand 3. Loam sand
4. Facing sand 5. Parting sand 6. Core sand
20. What are the elements in gating system?
1) Pouring cup 2) Sprue 3) Runner 5)Gate 6) Riser.
21. What is the function of riser?
After the mould is filled up, the molten metal rises into the riser.
It supplies molten metal to the mould during shrinkage of
casting and thus correct size casting can be obtained.
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29. List out the core binders. Give an example.
1) Oil binders : Linseed oil
2) Water soluble binders : Starch and dextrin
3) Resin binders : Phenol formaldehyde and urea
30. List out the steps in core making.
1) Core sand preparation 2) Core moulding
3) Baking 4) Core finishing
31. What are the types of cores?
1. Green sand core 2. Horizontal core 3. Vertical core
4. Balanced core 5. Hanging core 6. Drop core
32. List out the ovens used for heating the core.
1) Batch type ovens 2) Continuous type ovens 3) Dielectric type ovens
33. What are the allotropy stages of iron?
1) - iron 2) - iron 3) - iron 4) - iron
34. What are the different micro structures of steel?
1. Austenite 2. Ferrite 3. Cementite
4. Pearlite 5. Leduburite 6. Martensite
35. What is iron-carbon equilibrium diagram?
Iron – carbon equilibrium diagram is the graphical
representation of the phase changes undergone by iron with
respect to the carbon content and temperature on cooling or
heating. This diagram is drawn by taking the carbon content in
X-axis and temperature in Y-axis.
36. What is hypo eutectoid steel and hyper eutectoid steel?
Steel containing carbon less than 0.8% is called hypo eutectoid
steel. Steel containing carbon exactly 0.8% is called eutectoid
steel. Steel containing carbon from 0.8% to 2% is called hyper
eutectoid steel.
37. What are uses of tap hole and tuyers in cupola furnace?
Tap hole is provided for taking out the molten metal.
Air for combustion of fuel is sent through the openings
called tuyers.
38. List out the furnaces used for melting of non-ferrous metals.
1. Pit furnace
2. Coke fired stationary furnace
3. Oil fired tilting furnace
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11. Give the difference between upset butt welding and flash
butt welding.
In upset butt welding, the metals to be welded are clamped in
copper jaws so that there is a light contact at the ends of metals.
In flash but welding, the metals to be welded are clamped in jaws
so that there is a small air gap between the ends of metals.
12. What is spot welding? Give its applications.
Spot welding is a type of resistance welding which is used
for joining overlapping sheet metals by making weld at
regular interval.
Boxes, cans, automobile frames and air conditioners can
be welded by spot welding.
13. What is seam welding? List out its applications.
Seam welding is a process of making weld continuously
between two overlapping sheet metals.
Seam welding is used for welding radiators, drums, leak
proof tanks, automobile silencers, etc.
14. What is thermit? Give the applications of thermit welding.
Thermit steel is a mixture of aluminium powder and iron
oxide in the ration of 1:3.
Thermit welding is used for joining heavy parts, rails, pipes,
shafts, cables and worn out machine frames.
15. What is solid state welding? Give its types.
Solid state welding is the process of joining metals in solid state
without melting them. The types of solid state welding are
1. Friction welding 3. Diffusion welding
2. Ultrasonic welding 4. Explosive welding
16. List out the applications and advantages of friction welding.
Applications:
Friction welding is used for welding aero engine parts
and gas turbine shafts. It is also used for welding pinions to
shafts, rods to yokes, flanges to pipes, etc.
Advantages :
1) The initial cost is low.
2) Dissimilar metals can be welded.
3) It is a simple and fast process.
4) High quality weld can be obtained.
5) The power consumption is less.
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3. No distortion occurs.
4. Heat treated components can be welded without
affecting its properties.
5. The weld is not affected by oxidation.
22. What is gas welding? Name the gases used in gas welding.
Gas welding is a process of joining metals by the heat of
the flame formed when oxygen burns with another gas
The following gases are used to produce flame in gas welding.
1) Oxygen – acetylene
2) Oxygen - hydrogen
3) Air- acetylene
23. List out the equipment need for gas welding.
1. Gas cylinders 2. Pressure regulators 3. Pressure gauges
4. Hoses 5. Welding torch
24. What are the three types of flames in gas welding?
1) Neutral flame 2) Carburising flame 3) Oxidising flame
25. What is neutral flame? Give its application.
The neutral flame is produced when equal quantity of
oxygen and acetylene gases are used.
Neutral flame is used for welding steel, cast iron,
aluminium, copper and stainless steel.
26. When carburising flame is produced? State its
applications.
Carburising flame is produced when the quantity of
acetylene is more than oxygen.
Carburising flame is used for welding steel, alloy steels,
non-ferrous metals, nickel and monel metal.
27. How oxidising flame is produced? List out its applications.
Oxidising flame is produced when the quantity of oxygen is
more than acetylene.
Oxidising flame is used for welding brass, bronze,
manganese and steel.
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28. Give the applications of oxygen cutting and arc cutting.
Oxygen cutting is used to cut and remove runner and riser
from steel castings.
Arc cutting is used for cutting cast iron, alloy steel and non-
ferrous metals.
29. What is hard facing? List out its applications.
Hard facing is a process of coating a hard metal powder on the
surface of soft metals.
Application
1. It is used for coating tungsten carbide and chromium
carbide on the surface of cutting tool.
2. It is used in reconditioning of worn out machine parts by
coating required metal on it.
3. It is used for coating hard metal in the die surface.
30. What is bronze welding? Give its applications.
Bronze welding is an intermediate process between
brazing and welding
Bronze welding can be done in cast iron, steel, copper,
bronze and brass.
31. Differentiate between soldering and brazing.
Soldering is the process of joining two similar or dissimilar
metals by using a low melting alloy called solder. Solder is
an alloy of tin and lead.
Brazing is the process of joining two similar or dissimilar
metals by using a high melting alloy called spelter. Spelter
is a mixture of copper and zinc alloy.
32. List out the types of brazing.
1. Torch brazing 3. Furnace brazing
2. Dip brazing 4. Induction brazing
33. What are the types of welded joints?
1. Butt joint 2. Lap joint 3. ‘T’ joint
4. Corner joint 5. Flange joint
34. What is edge preparation? Give shapes of edges.
Edge preparation is the process of making the edges to be
joined to correct shape. This gives a good welded joint.
Shapes of edges :
1) Square 2) Single and double 'V' 3) Single and double 'U'
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35. List out the non-destructive and destructive methods for
welded joints.
Non destructive testing methods :
i) Magnetic particle test ii) X-ray test iii) Ultrasonic test
Destructive testing methods :
i) Nick brake test ii) Bend test iii) Tensile test
36. What are the applications of magnetic particle test, X-ray
test and ultrasonic test.
Magnetic particle test is used to find out cracks and slag
inclusions.
X-ray test is used to fine out defects like porosity, blow
holes and cavities.
Ultrasonic test is used to find out defects like cracks, blow
holes and porosity by using ultrasonic waves.
37. List out the various defects in welding.
1) Incomplete fusion 2) Slag inclusion 3) Crack
4) Undercut 3) Porosity and blow holes
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33. Differentiate : i) Notching ii) Slitting
Notching is the operation of cutting small notches at the
edge of the sheet metal.
Slitting is the operation of cutting a sheet metal in straight
line to required length.
34. Define : a) Lancing b) Shaving
Lancing is the operation of cutting a sheet metal through a
small length and bending it.
Shaving is the operation of finishing the components made
in sheet metal operations by removing the burrs and
irregularities.
35. What is powder metallurgy?
Powder metallurgy is the process of making components with
required properties and shape by mixing metal and non-metal
powders.
36. List out the step by step procedure of making products in
powder metallurgy.
1) Manufacturing of metal powder 2) Blending or mixing
1. 3) Pressing or compacting 4) Sintering
2. 5) Finishing and sizing
37. What are the methods used for manufacturing metal powders?
1. Atomization 2. Electrolytic deposition
3. Chemical reduction 4. Machining
5. Shotting 6. Milling
7. Grinding
38. What are the applications of atomization and electrolytic
deposition?
Atomization is used for producing powder of metals having
low melting point such as aluminium, lead and zinc.
Metals powders of copper, iron, silver and zinc can be
produced electrolytic deposition method.
39. Define : i) Blending ii) Sintering
Blending or mixing is the process of combining metal and
non-metal powders with correct proportions to get required
properties.
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45. What are the design rules in powder metallurgy?
1. Small holes (less than 2mm diameter) should be
avoided.
2. Sudden changes in thickness should be avoided.
3. Narrow and deep sections should be avoided.
4. Holes should not be provided in the direction of pressing.
5. Threads, knurling and under cuts should not be formed
by compacting.
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43. What are rules for cutting LH and RH threads in lathe.
While cutting right hand threads, the lead screw rotates in
the same direction of the spindle. Tool (carriage) moves
towards the head stock.
While cutting left hand threads, the lead screw rotates in a
direction opposite to the spindle. Tool (carriage) moves
towards tail stock.
44. Define cutting speed. Write the formula for cutting speed.
The length of chip cut by a tool from a rotating work piece in
one minute is called cutting speed.
𝝅𝑫𝒏
Cutting speed, 𝑽 = m/min
𝟏𝟎𝟎𝟎
Where, 𝐷 – Diameter of work piece,
𝑛 – Rotating speed of work piece
45. Define : i) Feed ii) Depth of cut.
Feed is the distance moved by the tool per revolution of the
work piece
Depth of cut is the thickness of metal removed from the
work piece when the cutting tool is moved once.
46. What is semi-automatic lathes. Give its types.
In semi automatic lathes, loading, unloading and bringing
the tool to machining position are done manually. All other
operations are done automatically.
The following types of semi automatic lathes are available
1. Capstan lathe or ram type lathe
2. Turret lathe or saddle type lathe
47. List out the principal parts in capston lathe.
1) Bed 2) Head Stock 3) Cross slide
4) Turret head and saddle 5) Preset stops
48. What is turret head?
Turret head is an hexagonal block in which six tools can be
fitted at a time. It can be indexed about a vertical axis.
49. What is preset stops in turret lathe?
Six adjustable stops are provided in turret head to control
the length of travel of six tools.
The turret movement required for a particular tool is preset
by the adjustable stop.
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11. What are the methods of holding drill bits?
1) Fitting directly in the spindle
2) Using sleeve
3) Using socket
4) Using drill chuck
12. What is the use of sleeve in drilling?
If the taper shank of the drill is smaller than the spindle taper, a
sleeve can be used.
13. What is the use of socket in drilling?
If the taper shank of the drill is larger than the spindle taper, a
socket can be used.
14. What are the operations performed in drilling machine?
1. Drilling 5. Counter sinking
2. Reaming 6. Spot facing
3. Boring 7. Tapping
4. Counter boring
15. What is counter sinking?
Counter sinking is the process of producing a conical
enlargement at the end of a hole.
16. Define counter boring.
Counter boring is the process of enlarging the end of a hole
cylindrically.
17. What is spot facing?
Spot facing is the process of producing a smooth and flat
surface around a hole.
18. What is the use of deep hole drilling?
Deep hole drilling is used to drill deep holes in the parts like
crank shaft, cam shaft, rifle barrel, etc.
19. What is miniature drills?
The drills used for producing small holes are called micro drills
or miniature drills. Generally, the diameter of the drill will be
form 0.1mm to 3mm.
20. What are the needs for inspection?
1. To ensure the correctness of materials and components
with the established standards.
2. To meet the interchangeability of manufacture.
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35. List out the applications of feeler gauges.
1. It is used to measure the clearance between the tool and
work piece in the machines.
2. It is used in automobiles for adjusting the spark plug
clearance correctly.
3. It is used to measure the clearance between piston and
cylinder.
4. It is used for measuring the clearance between the guide
and guide ways in machines.
36. Mention the applications of radius gauges and pitch screw
gauges.
Radius gauge is highly useful for measuring and checking
the inside and outside radii of fillets and other round
surfaces.
Pitch screw gauge is used to identify or check the pitch of the
threads on different threaded items.
37. What is least count? How it is calculated in vernier caliper?
Least count is the smallest value that can be measured by
using an instrument.
Least count = Length of one main scale division –
Length of one vernier scale division
38. What are the uses of vernier height gauge and gear tooth
vernier?
Vernier height gauge is used to measure the height of the
work piece and to mark the specified dimension exactly on
the work piece.
Gear tooth vernier is used to measure the chordal thickness
of a gear tooth.
39. What is chordal thickness? Write down the formula for
addendum.
Chordal thickness is the thickness of a gear tooth at which the
pitch circle passes through it.
𝒛 𝟗𝟎
𝑨𝒅𝒅𝒆𝒏𝒅𝒖𝒎 = 𝒎 [ (𝟏 − 𝒄𝒐𝒔 ( ) + 𝟏 )]
𝟐 𝒛
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46. List out the uses of slip gauges.
1. Slip gauges are used for the calibration of precision
measuring instruments.
2. Slip gauges are used in setting sine bars for establishing
angles.
3. They are used to check comparators and optical inspection
devices.
4. They are used as auxiliary measuring system on milling
machine.
47. What are the types of sine bar?
1. Sine centre 2. Sine table 3. Compound sine table
48. Mention the uses of sine centre and compound sine table.
Sine centers are used for mounting conical work pieces
which cannot be held on a simple sine bar
Compound sine table is used to measure compound angles
of large work pieces.
49. What are the uses of sine bar?
Measuring unknown angle.
Setting up known angle.
Checking of unknown angles of heavy component.
50. Write the limitations of sine bar.
1. The accuracy of sine bars is limited by measurement of
center distance between the two precision rollers.
2. It cannot be used as a primary standard for angle
measurements.
3. Sine principle is fairly reliable at angles less than 15 o, but
becomes inaccurate as the angle increases.
4. Sine bar becomes impractical and inaccurate as the angle
exceeds 45o.
51. What is clinometer? Give its uses.
A clinometer is a special case of application of spirit level for
measuring the inclinations
Uses :
1. It is used for the measurement of an inclined plane with
respect to a horizontal plane
2. It is used for the measurement of the relative position of two
mutually inclined surfaces :
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52. What is vial?
Vial is a closed glass tube of accurate size in a spirit level, which
is used for storing the liquid. It is graduated in linear scale and
the bubble moves inside it.
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